Guidewire with stiffness blending connection

ABSTRACT

Alternative designs, materials and manufacturing methods for connecting different guidewire sections together.

FIELD OF THE INVENTION

[0001] The present invention generally pertains to intravascular guidewires.

BACKGROUND OF THE INVENTION

[0002] Intravascular guidewires are commonly used in conjunction with intravascular devices such as balloon catheters to facilitate navigation through the vasculature of a patient. Because the vasculature of a human being may be very tortuous, guidewires often have a stiff proximal portion for pushability and torqueability, and a flexible distal portion for trackability.

SUMMARY OF THE INVENTION

[0003] To provide for a relatively stiff proximal portion and a relatively flexible distal portion, the proximal and distal portions of the guidewire may be formed of different materials. The present invention provides several alternative designs, materials and manufacturing methods for connecting different guidewire sections together.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004]FIG. 1 is cross sectional fragmentary view of a guidewire (pre-grinding), including a connection utilizing an overlapping tapered joint and a tubular connector for joining a proximal section and a distal section of the guidewire;

[0005]FIG. 2 is a cross sectional fragmentary view of the guidewire (post grinding) of FIG. 1;

[0006]FIG. 3 is a cross sectional fragmentary view of an alternative guidewire (post grinding), including a connection utilizing an overlapping joint (without a tubular connector) for joining a proximal section and a distal section of the guidewire;

[0007]FIG. 4 is a cross sectional fragmentary view of an alternative guidewire (post grinding), including a connection utilizing a butt joint and a tubular connector for joining a proximal section and a distal section of the guide wire;

[0008]FIG. 5 is a cross sectional fragmentary view of an alternative guidewire (post grinding), including a connection utilizing an overlapping joint and a tubular connector for joining a proximal section and a distal section of the guide wire; and

[0009] FIGS. 6A-6C are cross sectional fragmentary views of various end portions for use with the guidewire embodiment of FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

[0010] The following description should be read with reference to the drawings wherein like reference numerals indicate like elements throughout the several views. The detailed description and drawings illustrate examples of various embodiments of the claimed invention, and are not intended to be limiting.

[0011] Refer now to FIGS. 1-5 which illustrate cross sectional views of a portion of a guidewire 10 including a connection 20 joining a proximal guidewire section 14 and a distal guidewire section 16. FIG. 1 illustrates the guidewire 10 and the connection 20 before a final grinding step, and FIG. 2 illustrates the guidewire 10 and the connection 20 after the final grinding step, which provides a smooth outer profile. The embodiment of FIGS. 1 and 2 utilizes an overlapping tapered joint 12 and a tubular connector 18.

[0012] The embodiment of FIG. 3 is similar to the embodiment of FIGS. 1 and 2, except that the connection 20 between the proximal guidewire section 14 and the distal guidewire section 16 does not utilize a connector tube 18, but rather utilizes a connector material 19. The embodiment of FIG. 4 is similar to the embodiment of FIGS. 1 and 2, except that the connection 20 between the proximal guidewire section 14 and the distal guidewire section 16 does not utilize an overlapping joint 12, but rather uses a butt joint 13. The embodiment of FIG. 5 is also similar to the embodiment of FIGS. 1 and 2, except that the connection 20 between the proximal guidewire section 14 and the distal guidewire section 16 utilizes an overlapping joint 12 that is not tapered.

[0013] The proximal and distal guidewire sections 14/16 may have a solid cross-section as shown, or a hollow cross-section, and may be formed of metals or metal alloys suitable for metal joining techniques such as welding, soldering, brazing, crimping, friction fitting, adhesive bonding, etc. As used herein, the proximal section 14 and the distal section 16 may generically refer to any two adjacent guidewire sections along any portion of the guidewire. Furthermore, although discussed with specific reference to guidewires, the present invention may be applicable to almost any intravascular device having two adjacent metallic shaft sections. For example, the present invention may be applicable to metallic hypotube shafts for intravascular catheters (e.g., rapid exchange balloon catheters, stent delivery catheters, etc.) or metallic drive shafts for intravascular rotational devices (atherectomy catheters, IVUS catheters, etc.).

[0014] The proximal guidewire section 14 may be formed of relatively stiff material such as straightened 304 v stainless steel wire. Alternatively, proximal portion 14 may be comprised of a metal or metal alloy such as a nickel-titanium alloy, nickel-chromium alloy, nickel-chromium-iron alloy, cobalt alloy, or other suitable material. In general, the material used to construct proximal portion 14 may be selected to be relatively stiff for pushability and torqueability.

[0015] The distal guidewire section 16 may be formed of a relatively flexible material such as a straightened super elastic or linear elastic alloy (e.g., nickel-titanium) wire. Alternatively, distal portion 16 may be comprised of a metal or metal alloy such as stainless steel, nickel-chromium alloy, nickel-chromium-iron alloy, cobalt alloy, or other suitable material. In general, the material used to construct distal portion 16 may be selected to be relatively flexible for trackability.

[0016] The distal end 24 of the proximal portion 14 and the proximal end 26 of distal portion 16 (i.e., the joined ends) may form an overlapping tapered joint 12 as shown in FIGS. 1-3. Alternatively, the joined ends 24/26 may form a butt joint 13 as shown in FIG. 4. As a further alternative, the joined ends 24/26 may form an overlapping joint 12 that is not tapered as shown in FIG. 5. The non-tapered end portions 24/26 may have a uniform profile (diameter) 23 as shown in FIG. 6A, a bulbous portion 25 for purposes of mechanical interlocking as shown in FIG. 6B, or a helical form 27 for purposes of mechanical interlocking as shown in FIG. 6C. In each of the embodiments illustrated in FIGS. 1-3 and 5, the end portions 24/26 overlap to form an overlapping joint 12. The overlapping joint 12 blends the stiffness of proximal portion 14 and distal portion 16 by combining the properties of each end section 24/26 making up the cross section of the overlapping joint 12. Thus, the joint 12 forms a flexibility transition region that has a relative flexibility that is between the flexibility of the proximal portion 14 and the flexibility of the distal portion 16.

[0017] In the tapered embodiments illustrated in FIGS. 1-3, the ends 24/26 may be tapered or otherwise formed to have a mating geometry that gradually decreases in cross sectional area toward the middle of the connection 20. The tapered overlapping portion 12 may define a uniform or a non-uniform transition of the sections 24/26, depending on the transition characteristics desired. For example, the end sections 24/26 may be linearly tapered as shown, tapered in a curvilinear fashion, or tapered in a step-wise fashion. If tapered linearly as shown, the angle of the taper may vary. Using the longitudinal center axis of the guidewire 10 as a reference, as measured from the extreme ends of the end sections 24/26, the angle of the taper is acute (i.e., less than 90 degrees), and may be in the range of 5 degrees to 45 degrees, for example. Varying the angle of the tapered ends 24/26 also varies the length of the overlapping joint 12 in accordance with geometric principles. The length of the overlapping joint 12 may be selected to obtain a more (longer length) or less (shorter length) gradual transition in stiffness.

[0018] As mentioned previously, the proximal guidewire section 14 and the distal guidewire section 16 may be formed of different materials (i.e., materials having different moduli of elasticity) resulting in a difference in flexibility. For example, the proximal guidewire section 14 may be formed of stainless steel wire and the distal guidewire section 16 may be formed of nickel-titanium alloy wire, both having the same dimensions, resulting in a 3:1 difference in elastic modulus. Such a difference in elastic modulus (i.e., flexibility) may result in a stress concentration point during flexure and/or torsion that may have a tendency to kink. By virtue of the gradual transition in stiffness provided by the overlapping portion 12, stress is distributed along the entire length of the connection 20 thereby decreasing the probability that guidewire 10 may kink at the junction.

[0019] A gradual transition in stiffness may also allow the connection 20 to be located further distally. According to this embodiment, the distal portion 16 may be manufactured to be shorter than proximal portion 14. Including a relatively long proximal section 14 may advantageously increase the torquability and pushability of the guidewire 10. Although only one connection 20 is shown, additional connections 20 may be used to connect other guidewire sections of varying stiffness.

[0020] The connector 18 may comprise a tubular structure such as a hypotube as shown or a coiled wire. The connector 18 may have an inside diameter sized appropriately to receive the ends 24/26 of the proximal portion 14 and the distal portion 16, and an outside diameter sufficient to accommodate a final grinding procedure. The final diameter of the guidewire 10 and the connector 18 may be in the range of 0.010 to 0.018 inches, for example. By way of example, not limitation, the connector 18 may have a length of about 1.0 to 3.0 inches for an overlapping portion 12 of about 0.75 to 2.5 inches.

[0021] The connector 18 may be comprised of a metal or metal alloy, and may include radiopaque materials. Suitable metals and metal alloys include stainless steels, nickel-titanium alloys (e.g., nitinol), nickel-chromium alloys, nickel-chromium-iron alloys, cobalt alloys, nickel, or other suitable materials. Alternatively, connector 18 may be comprised of a polymer or a metal-polymer composite, including a radiopaque filler.

[0022] The word nitinol was coined by a group of researchers at the United States Naval Ordinance Laboratory (NOL) who were the first to observe the shape memory behavior of this material. The word nitinol is an acronym including the chemical symbol for nickel (Ni), the chemical symbol for titanium (Ti), and an acronym identifying the Naval Ordinance Laboratory (NOL).

[0023] Some types of alloys are particularly suitable for connector 18 for purposes of connecting a stainless steel proximal section 14 and a nickel titanium alloy distal section 16, or visa-versa. An example is a nickel-chromium-iron alloy available under the trade name INCONEL 625, which advantageously welds to both stainless steels and nickel-titanium alloys. INCONEL 625 may be obtained from California Fine Wire Company of Grover Beach, Calif., and has the following composition: Material Symbol % by wat Aluminum Al 0.140 Carbon C 0.070 Chromium Cr 21.900 Cobalt Co 0.010 Copper Cu 0.030 Iron Fe 2.790 Manganese Mn 0.030 Molybdenum Mo 9.150 Nickel Ni 62.000 Niobium Nb 3.540 Phosphorus P 0.005 Silicon Si 0.230 Sulfur S 0.009 Titanium Ti 0.250 Tantalum Ta 0.010

[0024] Another example of a suitable alloy which welds to both stainless steels and nickel-titanium alloys is available under the trade name ALLOY C276 from Fort Wayne Metals Research Products Corporation of Fort Wayne, Ind., which has the following composition: Material Symbol % by wat Carbon C 0.003 Chromium Cr 15.810 Cobalt Co 1.310 Copper Cu 0.100 Iron Fe 5.730 Manganese Mn 0.520 Molybdenum Mo 16.010 Nickel Ni 57.000 Phosphorus P 0.008 Silicon Si 0.020 Sulfur S 0.005 Tungsten W 3.570 Vanadium V 0.160

[0025] Another example of a suitable alloy which welds to both stainless steels and nickel-titanium alloys is available under the trade name ALLOY B2 from Fort Wayne Metals Research Products Corporation of Fort Wayne, Ind., which has the following composition: Material Symbol % by wat Carbon C 0.005 Chromium Cr 0.450 Cobalt Co 0.110 Copper Cu 0.030 Iron Fe 1.410 Manganese Mn 0.150 Molybdenum Mo 27.720 Nickel Ni 70.000 Phosphorus P 0.004 Silicon Si 0.020 Sulfur S 0.002 Tungsten W 0.140

[0026] To manufacture the connection 20 of the guidewire 10, the ends 24/26 of the proximal and distal guidewire sections 14/16 may be ground to form the desired shape (e.g., uniform diameter 23, bulbous portion 25, helix 27, or taper) to accommodate the overlapping joint 12. If a butt joint 13 is to be used, such a shape need not be ground. A recess step may be ground into the proximal and distal guidewire sections 14/16 to accommodate the connector tube 18. If a connector tube 18 is not to be used, such a recess step need not be ground.

[0027] For the embodiments utilizing a connector tube 18, the connector tube 18 is positioned over one of the ends 24/26 of the proximal and distal guidewire sections 14/16. The distal end 24 of the proximal portion 14 and proximal end 26 of the distal portion 16 are then positioned adjacent one another in an overlapping 12 or an end-to-end 13 arrangement. The proximal and distal guidewire sections 14/16 and the connector tube 18 may be bonded, welded (e.g., resistance or laser welded), soldered, brazed, or otherwise connected by a suitable technique depending on the material selected for each component. Alternatively, the ends 24/26 and the connector tube 18 may be crimped together or may be sized to establish a friction fit therebetween. If a connector tube 18 is not used, the ends 24/26 may be bonded, welded (e.g., resistance or laser welded), soldered, brazed, or otherwise connected, using a connector material 19. Connector material 19 may be the same as or similar to the material of the connector 18. In all cases, because the connection 20 may reside within a catheter lumen during use, it is preferred that a permanent connection (as opposed to a releasable connection) be used.

[0028] It is to be appreciated that various welding processes may be utilized without deviating from the spirit and scope of the present invention. Examples of welding processes which may be suitable in some applications include LASER welding, resistance welding, TIG welding, microplasma welding, electron beam, and friction or inertia welding. LASER welding equipment which may be suitable in some applications is commercially available from Unitek Miyachi of Monrovia, Calif. and Rofin-Sinar Incorporated of Plymouth, Mich. Resistance welding equipment which may be suitable in some applications is commercially available from Palomar Products Incorporated of Carlsbad, Calif. and Polaris Electronics of Olathe, Kans. TIG welding equipment which may be suitable in some applications is commercially available from Weldlogic Incorporated of Newbury Park, Calif. Microplasma welding equipment which may be suitable in some applications is commercially available from Process Welding Systems Incorporated of Smyrna, Tenn.

[0029] Once connected, the connector tube 18 and the proximal and distal guidewire sections 14/16 are centerless ground to provide a smooth and uniform profile across the connection 20, and to straighten out small misalignments between the proximal and distal guidewire sections 14/16. Other portions of the guidewire 10 may be ground as well to provide the desired tapers and changes in diameter. Once finally ground, a flexible coil tip and/or a polymer jacket (optionally covering connection 20) may be placed on the guidewire 10, and a lubricious coating (e.g., hydrophylic) may be applied.

[0030] The centerless grinding technique may utilize an indexing system employing sensors (e.g., optical/reflective, magnetic) to avoid excessive grinding of the connection 20. In addition, the centerless grinding technique may utilize a CBN or diamond abrasive grinding wheel that is well shaped and dressed to avoid grabbing the connector 20 during the grinding process.

[0031] It should be understood that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of steps without exceeding the scope of the invention. The invention's scope is, of course, defined in the language in which the appended claims are expressed. 

What is claimed is:
 1. A guidewire, comprising: a proximal section having a distal end, wherein the distal end of the proximal section has a reduced size; a distal section having a proximal end, wherein the proximal end of the distal section has a reduced size, and wherein the proximal end of the distal section overlaps the distal end of the proximal section; and a connector disposed adjacent the distal end of the proximal section and the proximal end of the distal section, the connector adapted and configured for permanently joining the proximal section to the distal section.
 2. A guidewire as in claim 1, wherein the proximal section has a first flexibility and the distal section has a second flexibility, and wherein the distal end of the proximal section and the proximal end of the distal section overlap to define a region that blends the first flexibility with the second flexibility.
 3. A guidewire as in claim 1, wherein the reduced size portions have a uniform profile.
 4. A guidewire as in claim 1, wherein the reduced size portions have a taper.
 5. A guidewire as in claim 1, wherein the reduced size portions have an interlocking shape.
 6. A guidewire as in claim 2, wherein the proximal section is comprised of stainless steel.
 7. A guidewire as in claim 6, wherein the distal section is comprised of a nickel-titanium alloy.
 8. A guidewire as in claim 7, wherein the connector is comprised of a nickel-chromium-iron alloy.
 9. A guidewire as in claim 1, wherein the connector comprises a tubular member disposed about the distal end of the proximal section and the proximal end of the distal section.
 10. A guidewire as in claim 9, wherein the tubular connector has an outside diameter that is the same as an outside diameter of the proximal section.
 11. A guidewire as in claim 10, wherein the tubular connector has an outside diameter that is the same as an outside diameter of the distal section.
 12. A guidewire as in claim 1, wherein at least a portion of the connector is disposed between the tapered distal end of the proximal section and the tapered proximal end of the distal section.
 13. A guidewire, comprising: a proximal section having a distal end, wherein the distal end of the proximal section includes a flexibility transition region; a distal section having a proximal end, wherein the proximal end of the distal section includes a flexibility transition region; and a connector disposed adjacent the distal end of the proximal section and the proximal end of the distal section, the connector adapted and configured for joining the proximal section to the distal section.
 14. A guidewire as in claim 13, wherein the proximal section has a first flexibility and the distal section has a second flexibility, and wherein flexibility transition regions overlap to define a region that blends the first flexibility with the second flexibility.
 15. A guidewire as in claim 14, wherein the proximal section is comprised of stainless steel.
 16. A guidewire as in claim 15, wherein the distal section is comprised of a nickel-titanium alloy.
 17. A guidewire as in claim 16, wherein the connector comprises a nickel-chromium-iron alloy tube.
 18. A guidewire as in claim 13, wherein at least a portion of the connector is disposed between the flexibility transition regions.
 19. A method of manufacturing a guidewire, comprising the steps of: providing a proximal section having a distal end, and a flexibility transition region at the distal end; providing a distal section having a proximal end, and a flexibility transition region at the proximal end; and joining the flexibility transition regions.
 20. A method as in claim 19, further comprising the step of forming the flexibility transition regions.
 21. A method as in claim 19, wherein the step of forming the flexibility transition regions comprises reducing the size of the proximal and distal ends.
 22. A method as in claim 19, wherein the step of joining the flexibility transition regions includes overlapping the proximal and distal ends.
 23. A guidewire, comprising: a proximal section having a first flexibility; a distal section having a second flexibility; and means for joining the proximal section with the distal section such that the first flexibility and the second flexibility are blended.
 24. A guidewire, comprising: a proximal section comprising stainless steel; a distal section comprising nickel-titanium alloy; and a connector comprising a nickel-chromium-iron alloy which connects the proximal and distal sections. 